Floor panel

ABSTRACT

A floor panel with a substrate, including thermoplastic material, a decor provided thereon, and, on at least one pair of opposite edges, coupling parts realized at least partially from the substrate. The coupling parts allow a mechanical locking between two of such floor panels, where the substrate includes a rigid, non-foamed substrate layer of thermoplastic material.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 17/205,475, filed Mar. 18, 2021, which is a continuation of U.S.application Ser. No. 16/345,855, filed Apr. 29, 2019, now U.S. Pat. No.10,988,939, which is the national stage filing of internationalapplication PCT/IB2017/056855, filed Nov. 3, 2017, which claims thebenefit under 35 U.S.C. 119(e) to the U.S. provisional application62/420,094 filed on Nov. 10, 2016 and Belgium application BE 2016/5868,filed Nov. 22, 2016, which are incorporated herein by reference.

This invention relates to a floor panel and to a method formanufacturing a floor panel. More particularly, the invention relates toa floor panel of the type which comprises a substrate comprisingthermoplastic material, and a decor provided thereon, as well as, on atleast one pair of opposite edges, coupling parts realized at leastpartially from the substrate, said coupling parts allowing to effect amechanical locking, i.e. without using glue or the like, between two ofsuch floor panels. This type of floor panels allows forming a waterprooffloor covering in a smooth and user-friendly manner. Such floor coveringmay also be applied without any problems in humid rooms, such asbathrooms, contrary to wood-based laminate floor panels with, forexample, a MDF or HOF substrate, which are less suitable for suchapplications.

BACKGROUND OF THE INVENTION

Document WO 2013/026559 describes such floor panel, wherein thesubstrate comprises one or more substrate layers of soft or flexiblepolyvinyl chloride, abbreviated PVC. However, such floor panel entrainsa number of problems. For example, there is a not to be neglected riskof telegraphy effects. Herein, after a certain period of timeimperfections in the underlying surface or subfloor on which the panelsare installed will 30 become visible on the surface of the panels. Wheninstalling the panels in a room with much incident sunlight, such as averanda or the like, there is also a high risk of the occurrence ofpushed-up edges and/or the formation of gaps between the mutuallycoupled panels. This is the result of the expansion/shrinkage thesubstrate is undergoing with varying temperatures. Although the use of aglass fiber layer may increase the dimensional stability of the floorpanel, this often still has proven insufficient in order to avoid thelast-mentioned problems. Moreover, the panels are relatively flexibleand bendable, due to which the installation thereof cannot alwaysperformed equally smooth. Moreover, the lacquer layer present on theupper side of the panel mostly scores insufficient in the field of wearresistance, scratch resistance, stain resistance and the like.

The floor panel which is known from document WO 2014/006593 alreadytackles a number of the mentioned problems. It has a rigid substratelayer formed by means of extrusion, which comprises, on the one hand,high-density polyethylene, abbreviated HOPE, or PVC and, on the otherhand, powder of bamboo, wood and/or cork. This substrate layer is gluedtogether with a veneer layer, such as a decorative vinyl layer. Thisfloor panel already offers a considerably higher resistance againsttelegraphy effects. Due to the rigidity thereof, it is also easier toinstall. However, it also has disadvantages. So, the flatness of thefloor panel cannot be guaranteed. There is a considerable risk that itwill warp. Moreover, the floor panel seems to be sensitive for theforming of indentations in the upper side thereof, for example, whentable or chair legs are standing thereupon. Further, delaminationproblems may occur, wherein the veneer layer becomes detached from thesubstrate layer.

SUMMARY OF THE INVENTION

The invention has the aim of offering a solution to one or more of theaforementioned and/or other problems.

To this aim, the invention, according to a first independent aspectthereof, relates to a floor panel of the aforementioned type, with thecharacteristic that the substrate comprises a rigid substrate layer ofthermoplastic material and a glass fiber layer is present in the floorpanel. The inventor has found that applying a glass fiber layer with arigid substrate layer is extremely advantageous. It provides for areduced risk of warping of the panels. Moreover, there is a less highrisk of pushed-up edges and/or gap formation when installing the panelsin a veranda or the like. The expansion/shrink is still there, however,this seems to lead less to the last-mentioned disadvantageous effects.Herein, it is noted that the expansion as such does not pose a problem,as this can be counteracted by providing the necessary expansion spaces.

It is noted that by the term substrate reference is made to that portionof the floor panel which is situated underneath the decor or thepossible decor carrier.

The rigidity of the substrate layer preferably is obtained by making thethermoplastic material thereof rigid. This is possibly by using anappropriate amount of plasticizer or no plasticizers at all. Ifplasticizers are used, this preferably is in an amount of less than 15phr, less than 10 phr or less than 5 phr. It is noted that an amount ofplasticizers of less than 15 phr means that per 100 parts ofthermoplastic synthetic material less than 15 parts of plasticizers arepresent. Examples of plasticizers which can be applied arephthalate-based plasticizers, such as di-isononyl phthalate, abbreviatedDINP, or dioctyl phthalate, abbreviated DOP or DnOP, or, as analternative for phthalate-based plasticizers, di-octyl terephthalate,abbreviated DOTP, or di-isononyl-1,2-cyclohexane dicarboxylate,abbreviated DINCH.

The thermoplastic material of the rigid substrate layer preferablycomprises one or more of the following thermoplastic syntheticmaterials: PVC, polyethylene, HOPE, polypropylene, polyester,polyethylene terephthalate, abbreviated PET, polyurethane and/orelastomer. The most preferred synthetic material is PVC.

The thermoplastic material of the rigid substrate layer preferablycomprises an amount of filler. Fillers promote the stiffness of thepanels. Various kinds of fillers may be applied, whether or not incombination:

-   -   an inorganic filler, such as chalk, lime and/or talc;    -   an organic filler, such as wood, bamboo and/or cork; and/or    -   a mineral filler.

It is also noted that the filler talc is particularly advantageous.Namely, it has shown that this filler has a positive effect on thedimensional stability of the panel.

The percentage of filler preferably is situated between 30 and 70percent by weight or between 45 and 65 percent by weight. Herein, it isnoted that the percentage by weight is considered in respect to thetotal weight of thermoplastic material in the substrate layer.

The proportion of filler preferably is at least 40 percent by weight,more preferably at least 50 percent by weight and still more preferablyat least 60 or at least 70 percent by weight. It has shown that suchrather high proportion of filler increases the dimensional stability ofthe substrate layer.

The thermoplastic material of the rigid substrate layer may comprise animpact modifier, a stabilizer, such as a Ca/Zn stabilizer, and/or acolor pigment, such as carbon black.

It is also noted that the thermoplastic material of the substrate layermay or may not be recycled material.

Preferably, the rigid substrate layer is not or almost not foamed. Theinventor has found that such substrate layer does not only offer abetter resistance against telegraphy effects than foamed layers, butalso against indentation. It is also noted that almost not foamed meansthat the density of the unfoamed thermoplastic material by foaming isreduced by maximum 10% and preferably by maximum 5% or by maximum 2%.The density of the not or almost not foamed substrate layer preferablyis situated between 1300 and 2000 kg per cubic meter or between 1500 and2000 kg per cubic meter.

However, it is not excluded that the rigid substrate layer is foamed. Infact, the inventor has found that foaming has a positive influence onthe dimensional stability. Preferably, the density reduction is morethan 10%. This means that the density of the unfoamed thermoplasticmaterial is reduced by more than 10% by foaming.

The rigid substrate layer can be formed by means of various techniques,such as strewing, extrusion or calendering processes. The strewingprocess, which as such is known from documents WO 2013/179261 and BE2015/5572, is preferred. In fact, the flatness of the substrate layercan be guaranteed better by such process.

The glass fiber layer may relate, for example, to a glass fiber fleece,a glass fiber cloth or a glass fiber net.

The glass fiber layer preferably adjoins the rigid substrate layer. Inthis position, the glass fiber layer may best counteract the possiblewarping or dimensional deformation of the substrate layer.

The glass fiber layer preferably is at least partially impregnated witha thermoplastic material of the rigid substrate layer. This provides fora good embedding of the glass fiber layer, due to which the workingthereof is more effective. The risk of delamination is reduced as well.

It is also noted that the glass fiber layer preferably relates to aglass fiber fleece. Such type of glass fiber layer is bonding better tothe substrate layer. A better impregnation is possible as well.

The substrate may comprise a second rigid substrate layer ofthermoplastic material.

This substrate layer may show one or more of the characteristics of thefirst-mentioned substrate layer.

Preferably, the glass fiber layer is adjacent to the first-mentioned aswell as to the second substrate layer. Herein, the glass fiber layer issituated between the two substrate layers. This can be obtained indifferent manners.

It is preferred that the two rigid substrate layers are provided bymeans of a strewing treatment. In this case, the one substrate layer canbe strewn, the glass fiber layer can be provided thereon, and the othersubstrate layer can be strewn on this complex. Subsequently, the wholecan be consolidated. Such process is known as such from document WO2013/179261. It offers the advantage that the glass fiber layer can beembedded very well between the two substrate layers.

Another possibility is the one wherein the one substrate layer isprovided by means of a strewing treatment, the glass fiber layer isprovided thereon, this complex is consolidated and the other substratelayer only then is provided on this consolidated complex. Such processis known from document WO 2016/079225. It offers the advantage that therisk of deformation and/or damage of the glass fiber layer can beminimized, as a press element of the possibly employed press device canbe directly brought into direct with the glass fiber layer. The othersubstrate layer may be provided, for example, by means of a calenderingtechnique.

Still another possibility is manufacturing the two rigid substratelayers by means of extrusion. In that case, the extruded substratelayers and the glass fiber layer can be stacked on top of each other andsubsequently can be bonded to each other. The mutual bonding can beperformed in a press device, for example, in a single-daylight ormulti-daylight press.

Another option is forming the one substrate layer by means of extrusion,transporting this extruded substrate layer and providing the glass fiberlayer during said transport on said extruded substrate layer. Anadvantage of this process in respect to the preceding one is that it canbe performed continuously. For example, the one substrate layer can betransported along guide rollers and the glass fiber layer can besupplied along with the substrate layer between these guide rollers. Theother substrate layer can be provided afterwards on the glass fiberlayer. Or it is possible to provide this substrate layer together withthe glass fiber layer on the one substrate layer during the transportthereof.

The glass fiber layer can be untreated. However, it is also possiblethat the glass fiber layer is pretreated. This latter may provide for abetter connection with the substrate layer or layers to which the glassfiber layer is adjacent. The pretreatment can include that a coating isprovided on the glass fiber layer or that the glass fiber layer isimpregnated. The coating or the impregnation material may relate to aplastisol, preferably a PVC plastisol. The pretreatment can take placein an offline step.

The weight of the glass fiber layer can be situated between 30 and 100grams per square meter. However, preferably this weight is lower than 65grams per square meter. This offers the advantage that the glass fiberlayer can be embedded easier and faster into the substrate. Moreover,such more light-weight glass fiber results in only a slight to noreduction of the dimensional stability, at least not as the one appliedwith rigid substrate layers, as the inventor, rather unexpectedly, hasfound.

In the floor panel preferably a second glass fiber layer is present. Theuse of more than one glass fiber layer has proven more effective thanthe use of a single glass fiber layer. The second glass fiber layer mayshow one or more of the characteristics of the first-mentioned glassfiber layer.

In particular, the first as well as the second glass fiber layer have aweight lower than 65 or at most 50 grams per square meter. This has apositive influence on the processing speed and practically nodetrimental influence on the dimensional stability, at least not in theapplication with rigid substrate layers.

The two glass fiber layers preferably are situated offset from thecenter of the floor panel. In this manner, their effect is betterdistributed over the floor panel. Preferably, the one glass fiber layeris situated in the lower half of the floor panel, while the other glassfiber layer is situated in the upper half.

The two glass fiber layers preferably are situated at a verticaldistance from each other of at least ⅕ times or at least ¼ times thethickness of the floor panels. This provides for a good distribution ofthe effect of the glass fiber panels over the overall thickness of thefloor panel. Most preferably, they are situated at a vertical distancefrom each other of approximately ⅓ the thickness of the floor panel.

Preferably, the two glass fiber layers enclose the first substratelayer. Herein, the upper side thereof is bordered by the one glass fiberlayer, and the lower side thereof by the other glass fiber layer. Thethickness of the first substrate layer in this case preferably is atleast ⅕, at least ¼ or approximately ⅓ times the overall thickness ofthe floor panel. The two glass fiber layers preferably are situatedoffset from the center of the floor panel, such that the center line ofthe floor panel in this case runs through the first substrate layer.

The one glass fiber layer preferably is enclosed between the firstsubstrate layer and a second rigid substrate layer of thermoplasticmaterial, while the other substrate layer preferably is enclosed betweenthe first substrate layer and a third rigid substrate layer ofthermoplastic material. This results in a particularly balanced andstable sandwich structure. The second and the third substrate layer canshow one or more of the characteristics of the first substrate layer.The first substrate layer preferably is situated centrally, i.e., thecenter line of the floor panel passes therethrough, whereas the secondand third substrate layer preferably are situated in the center, withthe second substrate layer in the upper half and the third substratelayer in the lower half of the floor panel. The second and the thirdsubstrate layer preferably are made thinner than the first substratelayer, however, preferably the thickness thereof is at least ⅕ or atleast ¼ of the thickness of the first substrate layer. The thirdsubstrate layer preferably is made thicker than the second substratelayer, however, maximum 2.5 or maximum 2 times as thick.

The one or more rigid substrate layers of thermoplastic material form arigid part of the floor panel. This rigid part preferably has an overallthickness of at least 2 mm. Namely, the inventor has found that as fromsuch thickness the resistance against telegraphy effects and the bendingstiffness is very good. Still better the overall thickness of the rigidpart is at least 2.5 mm or at least 3 mm. the overall thickness of therigid part preferably is maximum 8 mm, maximum 6 mm or maximum 4 mm. Inthis manner, the weight of the panels can remain limited. The overallthickness of the rigid part preferably is situated between 2 and 8 mm,between 2 and 6 mm or between 2 and 4 mm. The overall thickness of therigid part preferably is at least 50%, at least 60% or at least 65% ofthe overall thickness of the floor panel.

The substrate preferably comprises a substrate layer which is moreflexible or compressible than the first rigid substrate layer. This moreflexible substrate layer offers the advantage that the sound, which iscreated when the installed floor panels are walked upon, can be damped.Preferably, this flexible substrate layer is situated between the firstsubstrate layer and the decor. Preferably, this more flexible substratelayer is situated directly underneath the decor or the possible decorcarrier on which the decor is provided. In that case, it also assists inefficiently obtaining deep relief structures in the upper side of thefloor panel. For this purpose, it is indeed desirable to deform thematerial underneath the decor, which is easier when this material isrelatively flexible.

The more flexible substrate layer preferably is constructed ofthermoplastic material, wherein PVC best is used as the thermoplasticsynthetic material, however, wherein the use of other syntheticmaterials, such as polyethylene, polypropylene, polyester, such as PET,polyurethane and/or elastomer, is not excluded. The flexibility of thissubstrate layer preferably is obtained by realizing the thermoplasticmaterial thereof as soft or semi-rigid. This is possible by using anappropriate amount of plasticizers, certainly in the case that PVC isapplied as the thermoplastic synthetic material. The amount ofplasticizers in the more flexible substrate layer preferably is at least15 phr and still better at least 20 phr. Examples of plasticizers whichcan be used, certainly in the case of PVC, are phthalate-basedplasticizers, such as DINP or DOP, or, as an alternative forphthalate-based plasticizers, DOTP or DINCH.

When realizing the more flexible substrate layer, an extrusion,calendering or strewing technique can be applied.

It is preferred that the more flexible substrate layer is connected tothe first or the possible second rigid substrate layer via thermallamination, which, compared to the use of glue or the like, restrictsthe risk of delamination. Preferably, this is performed by a calenderingprocess, for example, by means of a calendering device consisting ofmore than two calendering rollers.

However, it is not excluded that the more flexible substrate layer iscomposed of another material than thermoplastic material. For example,it is possible that this substrate layer relates to a carpet layer, or atextile layer in general, or is made of rubber or cork. In these cases,it is preferred that the respective substrate layer is connected to thefirst or possible second rigid substrate layer by means of glue or thelike, preferably a waterproof glue, such as hot-melt glue. Herein, it isalso noted that, in the case of, for example, a carpet layer, the decoractually is comprised in this carpet layer.

The thickness of the more flexible substrate layer preferably issituated between 0.5 and 3 mm, still better between 0.5 and 2 mm andbest between 0.5 and 1 mm, or between limits included, as with thesethicknesses the herein above-described advantages will show particularlywell.

The substrate may comprise a substrate layer at its lower side, whichlayer preferably is more flexible or more compressible than the firstrigid substrate layer. By such substrate layer situated at the lowerside of the substrate, the advantage is obtained that the noise that iscreated when the installed floor panels are walked upon, can be damped.This substrate layer can be composed of thermoplastic material, whereinthe use of synthetic materials, such as PVC, polyethylene,polypropylene, polyester, such as PET, polyurethane and/or elastomer, ispossible. The respective substrate layer preferably is foamed,considering that this can improve the sound-absorbing features thereof.A preferred embodiment of such substrate layer is one that comprises XPEor cross-linked polyethylene foam.

When realizing said substrate layer situated at the lower side of thesubstrate, an extrusion, calendering or strewing technique can be used.

It is an option to connect this substrate layer with the first orpossible third rigid substrate layer by thermal lamination, which,compared to the use of glue or the like, restricts the risk ofdelamination. However, it is not excluded that the respective substratelayer is connected to the first or possible third substrate layer inanother manner, such as with glue or the like, in which case preferablya waterproof glue, such as hot-melt glue, is used.

It is also not excluded that the backing layer is composed of anothermaterial than thermoplastic material. For example, it is possible thatthe backing layer relates to a textile layer or is composed of cork orrubber. In these cases, it is preferred that the backing layer isconnected to the core by means of glue or the like, preferably awaterproof glue, such as hot-melt glue.

The thickness of said substrate layer located at the lower side of thesubstrate preferably is situated between 1 and 4 mm, still betterbetween 1 and 3 mm and best between 1 and 2 mm, limits included, whereina thickness of approximately 1.5 mm has proven ideal.

The decor preferably relates to an imprinted or printed decor, whereinthis imprinted or printed decor best depicts a natural product, such aswood or stone. In the case of wood, the decor can depict, for example,wood nerves and/or wood pores. For imprinting or printing, any of thefollowing techniques can be used: offset printing, rotogravure printingand a digital printing technique, wherein, for example, a digitalprinter or inkjet printer is employed.

The decor can be imprinted or printed on a decor carrier. Or the decorcan be imprinted or printed directly on the substrate, in which casethis relates to a so-called “direct print”. Herein, it is possible thatthe substrate is provided with a base coat or primer, possibly aplurality of base coats or primers, prior to imprinting or printingthereon.

When the decor is imprinted or printed on a decor carrier, thispreferably relates to a foil or film, which can be thermoplastic. Thismay relate, for example, to a foil or film of PVC, polyethylene,polypropylene, polyurethane, or polyester, such as PET.

It is also possible that the decor carrier relates to a cellulose-basedlayer, preferably impregnated with a resin. For example, thecellulose-based layer relates to paper, such as standard paper or akraft paper. The resin preferably comprises melamine resin and/or aphenolic resin.

It is also noted that, in the case that the decor carrier relates to acellulose-based layer, also one or more cellulose-based layers, such aspaper, can be present there underneath, which improves the rigidity ofthe floor panel. These one or more additional cellulose-based layerspreferably are impregnated with resin, such as melamine and/or phenolicresin.

As an alternative for an imprinted or printed decor, for example, aveneer of wood or stone can be provided on the substrate, which thenforms the decor. Preferably, the possible wood veneer is treated, suchthat it is waterproof or largely waterproof.

Preferably, the floor panel comprises a wear and/or lacquer layerprovided on the decor for protecting the decor and for preventing itfrom wear. Preferably, these layers are transparent or translucent, suchthat the decor remains visible.

The wear layer preferably relates to a foil or film, which best isthermoplastic. This may relate, for example, to a foil or film of PVC,polyethylene, polypropylene, polyurethane or polyester, such as PET. Thethickness of such foil or film preferably is situated between 250 and750 micrometers, limits included. This type of wear layer preferably isapplied in the case that the decor is imprinted or printed on a foil orfilm.

It is also possible that the wear layer relates to a cellulose-basedlayer, preferably impregnated with a resin. For example, thecellulose-based wear layer relates to paper, such as standard paper or akraft paper. The resin preferably comprises melamine resin and/or aphenolic resin. Preferably, the cellulose-based wear layer compriseswear-resistant particles, such as ceramic particles or corundum. Thistype of wear layer preferably is applied in the case that the decor isimprinted or printed on a cellulose-based layer.

The lacquer layer preferably is realized on the basis of urethaneacrylates, polyester acrylates and/or epoxide acrylates. Preferably,this relates to a lacquer layer which can be hardened by means of UVradiation or excimer radiation. The lacquer layer can comprise ceramicparticles, such as aluminum oxide and/or silica. The lacquer layer canbe provided prior or after forming the possible relief in the upper sideof the floor panel. Certainly, with a rather deep relief, for example,relief reaching deeper than 100 or 250 microns, it is advantageous toprovide the lacquer layer prior to forming the relief, such as knownfrom document BE 2016/5732, considering that this helps preventinginterruptions in the lacquer layer. This certainly proves its usefulnesswhen applying high-gloss wear layers, such as wear layers of PVC, as inthis manner the occurrence of blinking spots resulting from such wearlayers can be avoided, such as described in document BE 2016/5732.

It is also noted that a plurality of lacquer layers can be present abovethe decor. This is particularly advantageous in the case that a reliefis provided in the upper side of the floor panel. In that case, a firstlacquer layer can be provided prior to forming the relief, in order toprovide for that these lacquer layer does not show any interruptions andto prevent the occurrence of blinking spots, and a second after therelief has been formed, wherein for this second lacquer layer a harderlacquer can be applied, which principle is known as such from BE2016/5732.

It is also noted that the invention allows applying stiffer lacquers.This is because of the presence of the rigid substrate layer. In fact,this substrate layer can counteract the crimp to which the lacquer issubject, without the panel thereby warping or deforming. The applicationof stiffer lacquers offers the advantage that they are more effectiveand provide for a better mechanical and chemical resistance.

The upper side of the floor panel can show a relief simulating thetexture of a natural product, such as wood, stone or ceramics. In thecase of wood, the relief may simulate, amongst others, wood nervesand/or wood pores. Possible bevels on one or more of the edges of theupper side of the floor panel do not belong to such relief and are notconsidered as forming part of the relief, in view of the fact that theyare not directed to simulating a natural texture, but rather toachieving a plank effect. The relief can be provided by means ofmechanical and/or chemical embossing.

The relief preferably has a maximum relief depth which is larger than100 microns and still better is larger than 200 or 250 microns. Suchdeep relief provides for that the floor panel will look and feel verynatural. With such deep relief, it is particularly advantageous when amore flexible substrate layer, as described herein above, is applied. Infact, such substrate layer can be easily deformed or impressed in orderto form the deep relief.

In the case that a relief is formed in the upper side of the floorpanel, best a wear layer is present in which the relief extends. It ispossible that the relief, certainly with a deep relief, extends in thewear layer, however, up into the substrate, preferably up into thepossible more flexible substrate layer.

The relief may or may not be performed in register with the decor.Performing in register entrains the advantage that a more naturallylooking and feeling floor panel is obtained. Various techniques areknown in order to realize such “in register” embodiment, in particularfrom the following documents: EP 2 636 524, EP 2 447 063 and EP 2 447064.

It is noted that, in the case that a veneer of wood or stone is providedabove the substrate, the upper side of the floor panel automatically isgiven a relief with the texture of wood or stone, respectively.

The upper side of the floor panel can comprise a bevel on one or moreedges thereof. This may relate to a bevel which does not reach deeperthan the possible wear layer. However, it is possible that the bevelreaches deeper than the wear layer, for example, up into the substrate,in which case the bevel preferably is decorated. This is possible byproviding a separate decoration on the bevel, i.e., a decorationseparate from the decor, such as a lacquer, paint or transfer foil. Orthe decor may extend uninterruptedly over the bevel. In that case, thismay relate to a so-called “pressed bevel”, wherein the bevel is formedby impressing the upper side of the floor panel, including the decor, inthe proximity of an edge thereof.

The floor panel preferably shows one or more of the followingcharacteristics:

the floor panel bends under the own weight thereof less than 10 cm permeter and still better less than 5 cm per meter; and/or

the floor panel shows a modulus of elasticity or Young's modulus of atleast 2000 N per square millimeter, at least 3000 N per squaremillimeter or at last 3500 N per square millimeter.

The bending can be measured by fixedly clamping the floor panel on oneextremity thereof and measuring the bending of the remaining freeportion. In the case of an oblong rectangular panel, the fixedly clampedextremity may concern, for example, one of the longitudinal extremities.

The modulus of elasticity has to be understood as the one at a roomtemperature of 25 degrees Celsius.

The overall thickness of the floor panel preferably is situated between3 and 10 mm, or between 3 and 8 mm, or between 3.5 and 8 mm, or between3.5 and 6 mm, or between 4 and 6 mm, limits included, wherein an idealthickness is about 4.5 mm.

The mechanical locking effected by the coupling parts in the coupledcondition of two of such floor panels can be operative at least orexclusively in the horizontal direction, i.e., the direction in theplane of the coupled floor panels which is perpendicular to the couplededges. This horizontal locking can be realized by cooperating lockingsurfaces. The zone in which these locking surfaces cooperate, preferablyis situated at least partially or entirely in the first, the possiblesecond or the possible third rigid substrate layer, which offers theadvantage that a strong locking can be provided and the formation ofgaps can be minimized. It is also a possibility to situate the glassfiber layer at the height of this zone, which improves the strength ofthe locking.

The mechanical locking effected by the coupling parts in the coupledcondition of two of such floor panels, can be operative at least orexclusively in the vertical direction, i.e., the direction perpendicularto the plane of the coupled floor panels. This vertical locking can berealized by cooperating locking surfaces, wherein the zone in whichthese locking surfaces cooperate, preferably is situated at leastpartially or entirely in the first, the possible second or the possiblethird rigid substrate layer, which offers the advantage that a stronglocking can be provided, and the formation of gaps can be minimized. Itis also a possibility to situate the glass fiber layer at the height ofthis zone, which improves the strength of the locking.

It is preferred that both a horizontal and a vertical locking arepresent, best realized by cooperating locking surfaces, wherein the zoneor zones in which the locking surfaces cooperate preferably are situatedat least partially in the first, the possible second or the possiblethird rigid substrate layer. The glass fiber layer can be situated atthe height of a zone in which locking surfaces cooperate. In the casethat there are a plurality of zones in which locking surfaces cooperate,these glass fiber layers, when using a plurality of glass fiber layers,or at least a part of these glass fiber layers, may be situated at theheight of the aforementioned zones.

The coupling parts can be realized as a tongue and groove connection,the groove being bordered by an upper and a lower lip. This connectionpreferably comprises locking elements, for example, in the form of aprotrusion at the lower side of the tongue and a recess in the upperside of the lower lip, which, in the coupled condition, counteract themoving apart of the tongue and the groove in the horizontal direction.Preferably, this tongue and groove connection shows one or more of thefollowing characteristics, as far as they are not contradictory, whichcharacteristics all increase the stability and strength of the locking:

the upper lip is at least partially realized from the first or thepossible second rigid substrate layer;

the lower lip is at least partially realized from the first or thepossible third rigid substrate layer;

the center line through the tongue is situated in the first rigidsubstrate layer;

the most inwardly located point of the groove is situated in the firstrigid substrate layer;

the zone where the upper side of the tongue cooperates with the lowerside of the upper lip is situated at least partially or entirely in thefirst or the possible second rigid substrate layer;

the zone where the possible locking elements cooperate is situated atleast partially or entirely in the first or the possible third rigidsubstrate layer;

the glass fiber layer is situated at the height of the zone where theupper side of the tongue cooperates with the lower side of the upperlip;

the glass fiber layer is situated at the height of the zone where thepossible locking elements cooperate;

the glass fiber layer is situated on the center line through the tongue;the glass fiber layer is situated at the height of the most inwardlylocated point of the groove;

in the case that the zone where the upper side of the tongue cooperateswith the lower side of the upper lip is situated at another locationthan the zone where the possible locking elements cooperate, preferablyat least two glass fiber layers are present, wherein it is preferablyvalid that the one glass fiber layer is situated at the height of thezone where the upper side of the tongue cooperates with the lower sideof the upper lip, and the other is situated at the height of the zonewhere the possible locking elements cooperate;

the glass fiber layer extends uninterruptedly or continuously throughthe lower lip or the upper lip; and/or

the glass fiber layer extends uninterruptedly or continuously in atleast one of the coupling parts.

The coupling parts realized as a tongue and groove connection preferablyare selected from the following types:

the type wherein the coupling parts are configured such that they allowcoupling two of such floor panels at the respective edges by means of aturning movement, wherein the floor panel with the tongue, from aninclined position in which the tongue already is partially situated inthe groove, is turned downward in order to bring the tongue completelyinto the groove and couple the respective edges to each other;

the type wherein the coupling parts are configured such that they allowcoupling two of such floor panels at the respective edges by means of asubstantially linear movement in the plane of the floor panels andsubstantially perpendicular to the respective edges, preferably with theperformance of a snap action;

the type wherein the coupling parts are configured such that they allowcoupling two of such floor panels at the respective edges both by meansof a turning movement as described herein above and by means of asubstantially linear movement in the plane of the floor panels andsubstantially perpendicular to the respective edges, preferably with theperformance of a snap action.

It is also noted that the tongue and groove connection, in the case thatthe floor panel is square or oblong rectangular, can be applied at eachof the pair of opposite edges of the floor panel.

Alternatively, the coupling parts can be realized in the form ofhook-shaped parts, consisting of, on the one hand, an upward-directedhook-shaped locking part with a lip and an upward-directed lockingelement and, on the other hand, a downward-directed hook-shaped partwith a lip and a downward-directed hook-shaped part, which lockingelements, in the coupled condition of two of such floor panels,counteract the moving apart of the hook-shaped parts in the horizontaldirection. The mechanical locking effected by these hook-shaped partspreferably also is operative in vertical direction, and to this end theymay be provided with vertically active locking elements. Preferably, thehook-shaped parts show one or more of the following characteristics,which characteristics all improve the stability and strength of thelocking:

the lip of the downward-directed hook-shaped part is at least partiallyrealized from the first or the possible second rigid substrate layer;

the lip of the upward-directed hook-shaped part is at least partiallyrealized from the first or the possible third rigid substrate layer;

the zone where the upward-directed locking element cooperates with thedownward-directed locking element in order to effect the horizontallocking, is situated at least partially or entirely in the first or thepossible third rigid substrate layer;

the zone or zones where the possible vertically active locking elementscooperate, are situated at least partially or entirely in the first, thepossible second or the possible third rigid substrate layer;

the glass fiber layer is situated at the height of the zone where theupward directed locking element cooperates with the downward-directedlocking element in order to effect the horizontal locking;

the glass fiber layer is situated at the height of the zone or zoneswhere the possible vertical locking elements cooperate;

in the case that the zone, where the upward-directed locking elementcooperates with the downward-directed locking element in order to effectthe horizontal locking, is situated at another location than a zonewhere the possible vertically active locking elements cooperate,preferably at least two glass fiber layers are present, wherein it ispreferably valid that the one glass fiber layer is situated at theheight of the zone where the upward-directed locking element cooperateswith the downward-directed locking element in order to effect thehorizontal locking, and the other is situated at the height of the zonewhere the possible vertically active locking elements cooperate;

the glass fiber layer extends uninterruptedly or continuously in the lipof the downward-directed hook-shaped part or in the lip of theupward-directed hook-shaped part; and/or

-   -   the glass fiber layer extends uninterruptedly or continuously in        at least one of the hook-shaped parts.

The vertically active locking elements may or may not comprise aseparate insert, preferably an elastically deformable and/or movableinsert, which as such is known from, amongst others, the documents WO2006/043893, WO 2008/068245 and WO 2009/066153. The insert offers theadvantage that the strength of the vertical locking is largelyindependent of the material of the floor panel itself and that mostly astronger vertical locking can be provided compared to locking elementswhich are realized from the material of the floor panel itself.Certainly, in respect to reduction of the risk of the formation of gapsbetween the mutually coupled floor panels, such insert thus is useful.

The insert preferably is provided in a recess in the upward-directed orthe downward directed hook-shaped part. This recess preferably issituated at least partially in the first rigid substrate layer.

In the case that no use is made of such insert, the vertically activelocking elements preferably are realized from the material of the floorpanel itself and still better from the material of the first, thepossible second or the possible third rigid substrate layer. The rigidcharacter of this substrate layers provides for that these lockingelements, too, provide for a strong vertical locking.

The hook-shaped parts preferably can be hooked into each other by meansof a substantially linear movement perpendicular to the plane of thecoupled floor panels or to the plane of the floor covering.

It is also noted that the hook-shaped parts, in the case that the floorpanel is square or oblong rectangular, can be applied at each of thepair of edges of the floor panel.

Preferably, the floor panel is square or oblong rectangular and can becoupled to adjacent floor panels by means of the fold-down technique. Tothis aim, this floor panel comprises, on the one hand, on one pair ofopposite edges, coupling parts which are realized in the form of atongue and groove connection and which are of the type allowing tocouple this floor panel to an already installed, similar floor panel,which is situated in a preceding row, by means of a turning movement,and, on the other hand, on the other pair of edges, coupling parts whichare realized in the form of hook-shaped parts and which allow to couplethe respective floor panel, in one and the same turning movement, to analready installed, similar floor panel situated in the same row. It hasshown that this fold-down technique is excellently suited for installingthe floor panel according to the invention.

It is also noted that, instead of a glass fiber layer, any reinforcementlayer can be applied. Preferably, this is a reinforcement layer whichcomprises reinforcing fibers, such as carbon fibers.

According to an independent second aspect, the invention relates to afloor panel of the aforementioned type, with the characteristic that thesubstrate comprises a rigid, nonfoamed substrate layer of thermoplasticmaterial. Hereby, the floor panel, compared to floor panels with foamedsubstrate layers, is less sensitive to indentation effects, for example,under the influence of chair and/or table legs.

It is noted that this advantage also shows in the case that the rigidsubstrate is hardly foamed, i.e., in the case that due to the foamingthe rigid substrate layer shows a density reduction of maximum 10%.

According to an independent third aspect, the invention relates to afloor panel of the aforementioned type, with the characteristic that thesubstrate comprises a substrate layer of thermoplastic material, which,by thermal lamination, is connected to a more flexible substrate layerwhich is situated between the decor and the rigid substrate layer.Hereby the risk of delamination is reduced.

According to an independent fourth aspect, the invention relates to afloor panel of the aforementioned type, with the characteristic that inthe floor panel at least two glass fiber layers are present, each havinga weight of less than 65 g per square meter or even at most 50 g persquare meter.

It is also noted that each of the second to fourth aspects can becombined with one or more of the characteristics of the first aspectwithout necessitating that the floor panel must show the characteristicof this first aspect.

According to an independent fifth aspect, the invention relates to amethod for manufacturing a floor panel with a substrate, comprisingthermoplastic material, and a decor provided thereon, wherein the methodcomprises the following steps:

providing a first rigid substrate layer of thermoplastic material bymeans of a first strewing treatment;

providing a glass fiber layer on the strewn substrate layer;

providing a second rigid substrate layer of thermoplastic material onthe glass fiber layer, by means of a second strewing treatment;

consolidating the strewn substrate layers and the glass fiber layerunder the influence of pressure and/or heat;

providing, on the consolidated second substrate layer, a more flexibleor more compressible substrate layer of thermoplastic material byapplying this thermoplastic material in liquid condition.

The particularity of the method is that the rigid substrate layers areconsolidated and only then the more flexible substrate layer is providedthereon. This allows regulating the consolidation parameters, such aspressure and/or temperature, in an optimum manner in function of thefeatures of the thermoplastic material of the rigid substrate layers,which are different from those of the more flexible substrate layer,considering the difference in rigidity/flexibility.

The thermoplastic material of the first and/or second substrate layermay be strewn in the form of grains or powder. Preferably, thismaterial, or at least a part thereof, is strewn in granulate form,however, it may be advantageous to strew it as a dry blend, certainly inthe case that this material, or a part thereof, must be foamed. Such dryblend in fact guarantees the features of the foaming agents added to thematerial, as described in document BE 2015/5572, in a better manner.

The consolidation may be performed in a press device, preferably adouble-belt press device. This press device may comprise an S-roller,which can provide for a calibration of the strewn material.

Preferably, the more flexible substrate layer is provided on the secondsubstrate layer by means of a calendering device. The calendering devicepreferably comprises more than two calendering rollers.

It is clear that the method also can comprise providing the decor andpossible wear and/or lacquer layers.

The aforementioned layers preferably form a continuous material web,which finally is divided into individual pieces, for example, by meansof cutting treatments, for forming the floor panels.

After dividing into individual pieces, the floor panels, along one ormore edges, can be provided with coupling parts which allow effecting amechanical coupling between two of such floor panels. Providing thesecoupling parts preferably is performed by means of cutting tools, suchas milling tools.

The floor panel which is obtained according to the invention further mayshow one or more of the characteristics of the floor panel according tosaid first, second, third and/or fourth aspects.

It is noted that the present invention is not applicable with floorpanels only. It can be applied in an advantageous manner with any typeof panels, such as wall panels, ceiling panels or door panels.

The invention can also be applied more broadly than with panels only. Itcan be advantageously applied with any type of floor, wall, ceiling ordoor elements. Examples thereof are floor elements on roll orwall-to-wall floor elements, such as wall-to-wall vinyl.

It is also noted that with each of the mentioned value intervals thelimits are included, if not explicitly stated otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

With the intention of better showing the characteristics of theinvention, herein below, as an example without any limitative character,some preferred embodiments are described, with reference to theaccompanying drawings, wherein:

FIG. 1 represents a floor panel according to the invention;

FIG. 2 represents a cross-section according to line 11-11 in FIG. 1;

FIGS. 3 and 4 represent how the edges of FIG. 2 can be coupled;

FIG. 5, at a larger scale, represents what is indicated by F5 in FIG. 2;

FIGS. 6 to 13 represent variants of FIG. 2;

FIGS. 14 and 15 represent how floor panels can be coupled according tothe fold-down technique;

FIG. 16 represents coupling parts which can be applied with suchfold-down floor panels;

FIGS. 17 to 19 represent variants to FIG. 16;

FIG. 20 represents a method according to the invention; and

FIGS. 21 and 22 represent variants.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 represents a floor panel 1 according to the invention. Therepresented floor panel 1 comprises a decor 2, which relates to printedwood decor. This relates to an oblong rectangular floor panel 1, whichas a result has a pair of long edges 3-4 and a pair of short edges 5-6.Each pair of edges is provided with coupling parts, which are indicatedby the reference numbers 7-8 and 9-10, respectively.

The shape of the coupling parts 7-8 is evident from FIG. 2. This relatesto a tongue and groove connection comprising a tongue 11 and a groove12, the groove being bordered by an upper lip 13 and a lower lip 14. Thelower lip 14 protrudes to beyond the upper lip 13. Additionally, theconnection comprises locking elements 15-16, in the form of a protrusion15 on the lower side of the tongue 11 and an upward-directed lockingelement 16 in the portion of the lower lip 14 that protrudes beyond theupper lip 13, which, by cooperating locking surfaces 17-18, counteractthe moving apart of the tongue 11 and the groove 12 in the horizontaldirection H. The upper side 19 of the tongue 11 cooperates with thelower side 20 of the upper lip 13 in order to counteract the separationin the vertical direction V.

FIGS. 3 and 4 show how the coupling parts 7-8 can be coupled by means ofa turning movement (FIG. 3) as well as a substantially horizontal snapmovement (FIG. 4).

FIG. 2 also shows the construction of the floor panel 1. It isconstructed of a substrate 21, a decor carrier 22 with decor 2, a wearlayer 23 and a lacquer layer 24.

The substrate 21 Consists of two substrate layers 21A and 21B realizedon the basis of PVC.

The substrate layer 21A is rigid. For this purpose, no plasticizers arepresent in this layer 21A, or plasticizers are present in an amount ofless than 15 phr only. Examples of plasticizers which can be used havealready been mentioned. Also, the substrate layer 21A comprises aproportion of filler situated between 30 and 70 percent by weight.Preferably, chalk, talc and/or lime is used, possibly supplemented withwood, bamboo and/or cork particles. Further, the substrate layer 21A cancomprise an impact modifier, a stabilizer, such as a Ca/Zn stabilizer,and/or a color pigment, such as carbon black. The thickness T1 of thesubstrate 21A is at least 2 mm. The result is that the substrate layer21A has a high bending stiffness. This is advantageous, considering thatthe risk of warping of the floor panel 1 and of forming pushed-up edgesunder incident sunlight already is counteracted to a certain extent.

This risk is significantly reduced further due to the presence of theglass fiber fleece 25. Although it does not seem to be able to preventthe expansion/shrinkage of the substrate 21 with varying temperatures,it indeed counteracts the warping or pushing up. This actually is themost important, considering that the expansion/shrinkage as such can becounteracted by providing suitable expansion spaces, which also is knownas such in the field of the wood laminate floors. The glass fiber fleece25 is enclosed between the substrate layer 21A and 21B. In this manner,it can perform its function at its best. Possibly, the glass fiberfleece 25 is at least partially impregnated with thermoplastic materialof the substrate layers 21A and/or 21B. This provides for a strongembedding in the substrate 21, such that it can perform its functioneven better. The position of the glass fiber layer 25 provides for thatit extends uninterruptedly in both coupling parts 7-8. This is positivefor the effectivity thereof, certainly at the respective edges 3-4 ofthe panel 1.

The rigid substrate layer 21A is obtained by means of a strewingprocess. By such process, a very good connection with the glass fleece25 can be obtained. In such process, the glass fleece 25 can also have asupport function. Possibly, the glass fleece 25 can also form aseparation between the strewn layer 21A and the layer 21B in case thelatter also would be strewn. This is certainly useful prior toconsolidating, as this prevents a mutual mixing of the strewn materialamong the layers.

Also, the substrate layer 21A is not foamed. In comparison with foamedlayers, hereby a better resistance against telegraphy and indentationeffects is offered. The density of the layer 21A is situated between1300 and 2000 kg per cubic meter.

The zone where the upper side 19 of the tongue and the lower side 20 ofthe upper lip cooperate, is situated entirely in the rigid substratelayer 21A, just like the zone where the locking elements 15-16cooperate. This provides for that a strong mechanical coupling can beeffected, wherein gap formation will arise less easily. The upper lip 13is partially realized from the layer 17A, and the lower lip 14 evenentirely. This provides for a reduced risk of breaking of one or both ofthe lips 13-14. Certainly, with the lower lip 14, this is advantageousas this lip 14 may not break as a result of the possible bending it issubjected to during the coupling of the edges 3-4. Otherwise, thecoupling will be lost.

The substrate layer 21B is more flexible than the layer 21A. To thisaim, in this layer 21B more plasticizers are present, namely at least 15phr. This flexible layer 21B provides for that, regardless of therelatively stiff panel 1, no ticking sound is created when this panel 1is walked upon. Thus, due to the soft character, it has sound absorbingproperties. Moreover, such layer 21B is easier to deform in order tocreate a deep relief in the upper side of the panel 1. The proportion offiller in this layer 21B is situated between 30 and 70 percent byweight. Further, the substrate layer 21B can comprise an impactmodifier, a stabilizer, such as a Ca/Zn stabilizer, and/or a colorpigment, such as carbon black. The thickness T2 of the substrate layer21B is situated between 0.5 and 1 mm.

The layers 17A and 17B are connected to each other by means of thermallamination. In this manner, a reduced risk of delamination is obtainedin comparison with the use of glue or the like.

The decor carrier 22 on which the decor is printed relates to a PVC filmor foil.

The transparent wear layer 23 relates to a PVC layer with a thicknesssituated between 250 and 750 micrometers.

The overall thickness T of the floor panel 1 is situated between 3.5 and6 mm.

FIG. 5 better shows the lacquer 24 which is provided on the wear layer23. This relates to a lacquer realized on the basis of urethaneacrylate. The relief 26 provided in the upper side of the panel 1 isvisible, too.

FIG. 6 shows coupling parts 7-8 similar to those from FIG. 2, however,the substrate 21 is constructed differently. The layer 21A isconstructed similar to the layer 21A of FIG. 2, however, thinner.Anyhow, a second rigid substrate layer 21C is present in the substrate21A as well, which also is made of PVC. The substrate layer 21C containsno plasticizers, or plasticizers in an amount of less than 15 phr only.The substrate layer 21C also comprises a proportion of filler situatedbetween 30 and 70 percent by weight. Further, the substrate layer 21Ccan comprise an impact modifier, a stabilizer, such as a Ca/Znstabilizer, and/or a color pigment, such as carbon black. The overallthickness T1 of the substrate layers 21A and 21C is at least 2 mm. Theresult is that the whole of both substrate layers 21A and 21C gives ahigh bending stiffness to the panel 1, which even is increased by theenclosed glass fleece 25. The position of the glass fleece 25 is suchthat it extends uninterruptedly through both coupling parts 7-8. And itis positioned at the height of the center line of the tongue 11 and goesthrough the most inwardly located point of the groove 12. Thus, at thoselocations additional support is given, which is beneficial for thestrength of the tongue 11 and groove 12.

The rigid layers 21A and 21C are formed by means of a strewing processwhich is known as such from WO 213/179261. It offers the advantage thatthe glass fleece 25 can be embedded very well into the rigid whole, witha particularly stable sandwich as a result.

The rigid layer 21C also is not foamed.

FIG. 7 shows coupling parts 7-8 similar to those from FIG. 6, however,the substrate 21 is constructed differently. The substrate layers 21Aand 21C are constructed similar to the layers 21A and 21C of FIG. 6.However, there is a third rigid substrate layer 21D, which also is madeof PVC. The substrate layer 21D contains no plasticizers, orplasticizers in an amount of less than 15 phr only. Also, the substratelayer 21D comprise a proportion of filler situated between 30 and 70percent by weight. Further, the substrate layer 21D can comprise animpact modifier, a stabilizer, such as a Ca/Zn stabilizer, and/or acolor pigment, such as carbon black. The overall thickness T1 of thesubstrate layers 21A, 21C and 21D is at least 2 mm. The result is thatthe whole of the substrate layers 21A, 21C and 21D gives a high bendingstiffness to the panel 1, which even is increased by the presence of twoenclosed glass fleeces 25A and 25B. The two glass fleeces 25A and 25Bare located off the center of the panel 1 at a distance D from eachother of at least ⅕ the thickness T of the panel 1. The substrate layers21C and 21D are realized thinner than the center layer 21A, however,have a thickness of at least ⅕ the thickness of the center layer 21A.The result is a particularly balanced and stable sandwich construction.The substrate layers 21A, 21C and/or 21D as such may comprise aplurality of substrate layers and thus be multi-layered. The substratelayer 21A, for example, may comprise a plurality of substrate layerswhich may or may not have a mutually differing composition, such as amutually differing proportion of filler or plasticizer. The same isapplicable to the layers 21C and 21D and more generally to all substratelayers mentioned in this document.

The two glass fleeces 25A and 25B have a weight smaller than 65 gram persquare meter. This has a positive influence on the process speed andpractically no detrimental influence on the dimensional stability, atleast not in the application with rigid substrate layers.

FIG. 8 shows a variant of FIG. 7, wherein the substrate 21A at the lowerside comprises a sound-absorbing substrate layer 21E of XPE foam. Thethickness of this layer 21E is situated between 1 and 2 mm.

FIG. 9 shows a variant of FIG. 7, wherein the glass fleeces 25A-25B arepositioned somewhat differently. The glass fleece 25A goes centrallythrough the zone where the upper side 19 of the tongue 11 cooperateswith the lower side 20 of the upper lip 13, whereas the glass fleece 25goes centrally through the zone where the locking elements 15-16cooperate. This provides for an excellent horizontal and verticallocking.

FIG. 10 shows a variant of FIG. 9. The glass fleece 25A is positionedsimilarly, however, the glass fleece 25B extends uninterruptedly in thecoupling part 8. It extends continuously through the lower lip 14. Thisis beneficial for the strength of this lip 14.

FIG. 11 shows a similar construction of the substrate 21A as in FIG. 10,however, the coupling parts 7-8 have another configuration. The lowerside of the tongue 11 is convex, while the upper side of the lower lip14 is concave.

FIGS. 12 and 13 show two more variants, where the lower side of thetongue 11 and the upper side of the lower lip 14 comprise a flat part.

FIGS. 14 and 15 represent how floor panels 1 can be coupled to eachother by means of the fold-down technique.

To this aim, the short pair of edges 5-6 of the panel 1 is provided withthe coupling parts 9-10 shown in FIG. 16. Those are realized in the formof a downward-directed hook 27 and an upward-directed hook 28. Thedownward hook 27 has a lip 29 with a downward-directed locking element30, whereas the upward hook 28 has a lip 31 with an upward-directedlocking element 32. The locking elements 30 and 32 cooperate, vialocking surfaces 33-34, in order to counteract the moving apart of thehooks 27-28 in horizontal direction. The hooks 27-28 are also providedwith vertically active locking elements 35-36. The vertically activelocking element 35 is made as a separate insert, which is provided in arecess 37 in the downward hook 27. This recess is situated partially inthe rigid layers 21A and 21C. it is also possible to provide the insert35 in the upward hook 28.

The lip 29 is formed partially from the rigid layers 21A and 21C. Thelip 31 is formed entirely from the rigid layers 21A and 21D. The zonewhere the locking elements 30 and 32 cooperate is situated entirely inthe rigid layer 21A. All these measures are advantageous for thestrength of the locking. The zone where the insert 35 cooperates withthe locking element 36 is situated in the more flexible layer 21B.However, it is not excluded that this last zone is situated at leastpartially or entirely in the rigid layers 21A and/or 21C.

The glass fiber layer 25A is situated at the height of the recess 37.This provides for additional stability there, where the floor panel, dueto the recess 37, is somewhat weaker.

The glass fiber layer 25A extends continuously in the lip 31 of theupward-directed hook 28.

FIG. 17 shows a variant of FIG. 16. Here, the insert 36 is provided in arecess 37 in the upward hook 28. The zone where the insert 36 cooperateswith the locking element 35, however, indeed is situated in a rigidsubstrate layer, namely in the rigid layer 21A. This provides for a verygood vertical locking.

FIG. 18 shows a variant of FIGS. 16 and 17, wherein the verticallyactive locking elements are realized from the material of the panel 1.There, even two pairs of vertically active locking elements are present,namely the locking elements 35-36 as well as the locking surfaces 33-34,which provide for the horizontal as well as the vertical locking. Allthe vertical locking elements are made from the rigid layers 21A and21C. Moreover, the glass fleece is situated at the height of the zonewhere the locking elements 35-36 cooperate. The glass fleece 25B extendscontinuously through the lip 31. This provides for that the lip 31 isrealized very stable and the risk of damaging it, for example, duringthe elastic bending of the lip 31 during coupling, is very small, inspite of the recess provided in the lower side of the lip 31, whichrecess increases the bendability of the lip 31 and, thus, the ease ofinstallation.

FIG. 19 shows a variant of FIG. 18, wherein the vertically activelocking elements 35-36 are situated at the end of the lip 31. The glassfleece 25B goes therethrough.

FIG. 20 represents a method according to the fifth aspect of theinvention. This method can be used in order to obtain the substrateconstruction of the panels 1 of, for example, FIG. 7. By means ofstrewing treatments successively the rigid substrate layers 21D, 21A and21C are provided. The rigid thermoplastic material thereof is strewnonto a transport belt 39 by means of strewing devices 38. On the strewnlayers 21D and 21A a glass fleece 25B and a glass fleece 25A,respectively, is provided. To this aim, the glass fleeces 25A and 25Bare unrolled from rollers 40 and provided on the respective substratelayers 21D and 21A. The formed complex subsequently is transported to adouble-belt press 41, in which it is consolidated under the influence ofpressure and/or heat. The press device 41 comprises, in transportdirection, heating elements 42, an S-roller 43 and cooling elements 44.The heating elements 42 heat the complex brought into the press device41, as a result of which the individual layers can be connected to eachother more easily and better. The use of the S-roller 43 is advantageousas it provides for a calibration of the respective layers. The coolingelements 44 finally cool the consolidated complex, such that it can beprocessed more rapidly. Subsequently, the more flexible substrate layer21B is provided on the consolidated whole, by means of calenderingdevice 45 which consists of more than one calendering roller 46.

It is clear that in subsequent steps the decor carrier 22 with decor 2,the wear layer and the lacquer layer, 23 and 24, can be applied.

FIG. 21 shows a variant of FIG. 20. Here, the glass fleece 25 is broughtinto contact with a press element in the press device 43. This isdifferent to FIG. 20, where each glass fleece is enclosed between rigidsubstrate layers.

FIG. 22 shows another alternative manner of providing a glass fleece 25on a rigid substrate layer. Reference number 47 indicates an extrusiondevice with which the rigid substrate layer 21A is manufactured. Thissubstrate layer 21 subsequently is transported between guide rollers 48.The glass fleece 25 is wound off a roll 49 and provided, between two ofsuch guide rollers, on the substrate layer 21A. It is clear that thiswhole can be processed further and possibly can be supplemented withsubsequent substrate layers and/or glass fleeces. It is also noted thatthis technique and be applied in an advantageous manner with any type ofsubstrate layer of thermoplastic material, independently of whether thisrelates to a rigid, semi-rigid or flexible substrate layer.

The present invention further relates to several preferred embodimentsas defined in the below numbered paragraphs:

1.—Floor panel (1) with a substrate (17), comprising thermoplasticmaterial, a decor (2) provided thereon, and, on at least one pair ofopposite edges (3-4, 7-8), coupling parts (5-6, 9-10) realized at leastpartially from the substrate (17), said coupling parts allowing toeffect a mechanical locking between two of such floor panels (1),characterized in that the substrate (17) comprises a rigid substratelayer (17A) of thermoplastic material, and a glass fiber layer (25) ispresent in the floor panel (1).

2.—Floor panel according to paragraph 1, wherein the rigid substratelayer (17A) comprises plasticizers in an amount of less than 15 phr,less than 10 phr or less than 5 phr, or does not comprise anyplasticizers.

3.—Floor panel according to paragraph 1 or 2, wherein the thermoplasticmaterial of the rigid substrate layer (17A) comprises PVC.

4.—Floor panel according to any of the preceding paragraphs, wherein thethermoplastic material of the rigid substrate layer (17A) comprises aproportion of filler, which proportion preferably is situated between 30and 70 percent by weight or between 45 and 65 percent by weight.

5.—Floor panel according to paragraph 4, wherein the proportion offiller comprises an inorganic filler, such as chalk, lime and/or talc,and/or an organic filler, such as wood, bamboo and/or cork.

6.—Floor panel according to any of the preceding paragraphs, wherein therigid 25 substrate layer (17A) is not foamed.

7.—Floor panel according to paragraph 6, wherein the density of therigid substrate layer (17A) is situated between 1300 and 2000 kg percubic meter or between 1500 and 2000 kg per cubic meter.

8.—Floor panel according to any of the preceding paragraphs, wherein theglass fiber layer (25) relates to a glass fiber fleece.

9.—Floor panel according to any of the preceding paragraphs, wherein theglass fiber layer (25) adjoins to the rigid substrate layer (17A).

10.—Floor panel according to any of the preceding paragraphs, whereinthe substrate comprises a second rigid substrate layer (17B) ofthermoplastic material, which preferably is not foamed.

11.—Floor panel according to paragraph 10, wherein the glass fiber layer(25) is enclosed between the first and the second rigid substrate layer(17A-17B).

12.—Floor panel according to any of the preceding paragraphs, wherein asecond glass fiber layer (25B) is present in the floor panel (1).

13.—Floor panel according to paragraph 12, wherein the first and thesecond glass fiber layer (25A-25B) each have a weight smaller than 65 orat most 50 gram per square meter.

14.—Floor panel according to paragraph 12 or 13, wherein the first andthe second glass fiber layer (25A-25B) are situated off the center ofthe floor panel (1).

15.—Floor panel according to any of the paragraphs 12 to 14, wherein thefirst and the second glass fiber layer (25A-25B) are situated at avertical distance (V) of at least ⅕ times or at least ¼ times thethickness of the floor panel (T) from each other.

16.—Floor panel according to any of the paragraphs 12 to 15, wherein thefirst and the second glass fiber layer (25A-25B) enclose the rigidsubstrate layer (17A), which in this case preferably is situated in thecenter of the floor panel.

17.—Floor panel according to any of the paragraphs 12 to 16, wherein thefirst glass fiber layer (25A) is enclosed between the rigid substratelayer (17A) and the possible second rigid substrate layer (17B), and thesecond glass fiber layer (25B) is enclosed between the rigid substratelayer (17A) and a third rigid substrate layer (17C) of thermoplasticmaterial, which third rigid substrate layer (17C) preferably is notfoamed.

18.—Floor panel according to paragraph 17, wherein the second and thethird substrate layer (17B-17C) are made thinner than the first rigidsubstrate layer (17A), however, preferably have at least ⅕ times or atleast ¼ times its thickness.

19.—Floor panel according to paragraph 16 or 17, wherein the thirdsubstrate layer (17C) is made thicker than the second substrate layer(17B), however, preferably maximum 2.5 or maximum 2 times as thick.

20.—Floor panel according to any of the preceding paragraphs, whereinthe one or more rigid substrate layers (17A-17B-17C) of thermoplasticmaterial have an overall thickness of at least 2 mm.

21.—Floor panel according to any of the preceding paragraphs, whereinthe one or more rigid substrate layers (17A-17B-17C) of thermoplasticmaterial have an overall thickness of at least half of the overallthickness (T) of the floor panel (1).

22.—Floor panel according to any of the preceding paragraphs, whereinthe substrate, between the decor and the rigid substrate layer (17A),comprises a substrate layer (17D) of thermoplastic material which ismore flexible or more compressible than the rigid substrate layer (17A).

23.—Floor panel according to paragraph 22, wherein the more flexiblesubstrate layer (17D) is situated directly underneath the decor or thepossible decor carrier on which the decor is provided.

24.—Floor panel according to paragraph 21 or 22, wherein the moreflexible substrate layer (17D) is connected to the underlying part ofthe substrate (17) by means of thermal lamination.

25.—Floor panel according to any of the preceding paragraphs, whereinthe decor (2) relates to an imprinted or printed decor.

26.—Floor panel according to any of the preceding paragraphs, whereinthe floor panel (1) comprises a wear and/or lacquer layer (21 and/or 29)provided above the decor (2).

27.—Floor panel according to any of the preceding paragraphs, whereinthe floor panel (1) will bend under its own weight less than 10 cm permeter or less than 5 cm per meter.

28.—Floor panel according to any of the preceding paragraphs, whereinthe floor 10 panel (1) has a modulus of elasticity of at least 2000 Nper square millimeter.

29.—Floor panel according to any of the preceding paragraphs, whereinthe overall thickness (T) of the floor panel (1) is situated between 3.5and 6 mm.

30.—Floor panel according to any of the preceding paragraphs, whereinthe coupling parts (5-6) are realized as a tongue and groove connection,the groove (12) being bordered by an upper (13) and a lower lip (14),and wherein this connection comprises locking elements (15-16).

31.—Floor panel according to paragraph 30, wherein the tongue and grooveconnection shows one or more of the following features, as far as theyare not contradictory:

-   -   the upper lip (13) is at least partially realized from the first        (17A) and/or the possible second rigid substrate layer (17B);    -   the lower lip (14) is at least partially or entirely realized        from the first (17A) or the possible third rigid substrate layer        (17C);    -   the center line through the tongue (11) is situated in the first        rigid substrate layer (17A);    -   the most inwardly located point of the groove (12) is situated        in the first rigid substrate layer (17A);    -   the zone where the upper side of the tongue (11) cooperates with        the lower side of the upper lip (13) is situated at least        partially or entirely in the first (17A) or the possible second        rigid substrate layer (17B);    -   the zone where the locking elements (15-16) cooperate is        situated at least partially or entirely in the first (17A)        and/or the possible third rigid substrate layer (17C);    -   the glass fiber layer (25) is situated at the height of the zone        where the upper side of the tongue (11) cooperates with the        lower side of the upper lip (13);    -   the glass fiber layer (25) is situated at the height of the zone        where the locking elements (15-16) cooperate;    -   the glass fiber layer (25) is situated on the center line        through the tongue (11);    -   the glass fiber layer (25) is situated at the height of the most        inwardly located point of the groove (12);

in the case that the zone where the upper side of the tongue (11)cooperates with the lower side of the upper lip (13) is situated atanother location than the zone where the locking elements (15-16)cooperate, preferably at least two glass fiber layers (25A-25B) arepresent, wherein it is preferably valid that the one glass fiber layer(25A) is situated at the height of the zone where the upper side of thetongue (11) cooperates with the lower side of the upper lip (13), andthe other is situated at the height of the zone where the lockingelements (15-16) cooperate;

-   -   the glass fiber layer extends uninterruptedly or continuously in        the lower lip or in the upper lip; and/or    -   the glass fiber layer (25) extends uninterruptedly or        continuously in at least one of the coupling parts (5-6).

32.—Floor panel (1) with a substrate (17), comprising thermoplasticmaterial, a decor (2) provided thereon, and, on at least one pair ofopposite edges (3-4, 7-8), coupling parts (5-6, 9-10) realized at leastpartially from the substrate (17), said coupling parts allowing toeffect a mechanical locking between two of such floor panels (1),characterized in that the substrate (17) comprises a rigid, non-foamedsubstrate layer (17A) of thermoplastic material.

33.—Floor panel (1) with a substrate (17), comprising thermoplasticmaterial, a decor (2) provided thereon, and, on at least one pair ofopposite edges (3-4, 7-8), coupling parts (5-6, 9-10) realized at leastpartially from the substrate (17), said coupling parts allowing toeffect a mechanical locking between two of such floor panels (1),characterized in that the substrate comprises a rigid substrate layer(17A) of thermoplastic material, which, via thermal lamination, isconnected to a more flexible substrate layer (17D) which is situatedbetween the decor (2) and the rigid substrate layer (17A).

34.—Floor panel (1) with a substrate (17), comprising thermoplasticmaterial, a decor (2) provided thereon, and, on at least one pair ofopposite edges (3-4, 7-8), coupling parts (5-6, 9-10) realized at leastpartially from the substrate (17), said coupling parts allowing toeffect a mechanical locking between two of such floor panels (1),characterized in that in the floor panel at least two glass fiber layers(25A-25B) are present, each having a weight of less than 65 g per squaremeter or even at most 50 g per square meter.

35.—Method for manufacturing a floor panel (1) with a substrate (17),comprising thermoplastic material, and a decor (2) provided thereon,wherein the method comprises the following steps:

-   -   providing a first rigid substrate layer (17A) of thermoplastic        material by means of a first strewing treatment;    -   providing a glass fiber layer (25) on the strewn substrate layer        (17A);    -   providing a second rigid substrate layer (17B) of thermoplastic        material on the glass fiber layer (25), by means of a second        strewing treatment;    -   consolidating the strewn substrate layers (17A-17B) and the        glass fiber layer (25) under the influence of pressure and/or        heat;    -   providing, on the consolidated second substrate layer (17B), a        more flexible or more compressible substrate layer (17D) of        thermoplastic material by applying this thermoplastic material        in liquid condition.

36.—Method according to paragraph 35, wherein the consolidation isperformed in a press device (47).

37.—Method according to paragraph 35 or 36, wherein the more flexiblesubstrate layer (17D) is provided on the second substrate layer (17D) bymeans of a calendaring device.

38.—Method according to any of the paragraphs 35 to 37, wherein themethod also comprises providing the decor (2) and a possible wear and/orlacquer layer (21A and/or 29).

39.—Method according to any of the paragraphs 35 to 38, wherein theaforementioned layers form a continuous material web, which finally isdivided into individual pieces for forming the floor panels (1).

40.—Method according to any of the paragraphs 35 to 39, wherein themethod is employed for manufacturing a floor panel (1) according to anyof the paragraphs 1 to 34.

The present invention is in no way limited to the herein above-describedembodiments; on the contrary, such methods, floor panels and carriermaterial can be realized according to various variants without leavingthe scope of the present invention.

1. A floor panel comprising a substrate and a decor provided thereon,said substrate comprises a rigid substrate layer of thermoplasticmaterial, wherein said rigid substrate layer of thermoplastic materialis non-foamed, or wherein said rigid substrate layer of thermoplasticmaterial is foamed and shows a density reduction of maximum 10% due tosaid foaming, and wherein said thermoplastic material of the rigidsubstrate layer comprises a filler.
 2. The floor panel of claim 1,wherein said filler is chosen from the group of an inorganic filler, anorganic filler, a mineral filler, or combinations thereof.
 3. The floorpanel of claim 1, wherein said filler is present in said thermoplasticmaterial in an amount of between 30 and 70 percent by weight, preferablyof between 45 and 65 percent by weight.
 4. The floor panel of claim 1,wherein the proportion of filler is at least 40 percent by weight, morepreferably at least 50 percent by weight and still more preferably atleast 60 or at least 70 percent by weight.
 5. The floor panel of claim1, wherein said thermoplastic material of the rigid substrate layercomprises an impact modifier, a stabilizer, such as a Ca/Zn stabilizer,and/or a color pigment, such as carbon black.
 6. The floor panel ofclaim 1, wherein said thermoplastic material of the rigid substratelayer has a density of between 1300 and 2000 kg per cubic meter,preferably of between 1500 and 2000 kg per cubic meter.
 7. The floorpanel of claim 1, wherein the thermoplastic material of the rigidsubstrate layer comprises PVC.
 8. The floor panel of claim 1, whereinthe floor panel comprises a glass fiber layer, preferably a glass fiberfleece.
 9. The floor panel of claim 8, wherein the glass fiber layeradjoins to the rigid substrate layer.
 10. The floor panel of claim 1,wherein said substrate comprises a second rigid substrate layer ofthermoplastic material, and wherein said second rigid substrate layer ofthermoplastic material is non-foamed, or wherein said second rigidsubstrate layer of thermoplastic material is foamed and shows a densityreduction of maximum 10% due to said foaming.
 11. The floor panel ofclaim 1, wherein the decor relates to an imprinted or printed decor. 12.The floor panel of claim 1, wherein the floor panel comprises a wearand/or lacquer layer provided above the decor.
 13. The floor panel ofclaim 1, wherein the floor panel will bend under its own weight lessthan 10 cm per meter or less than 5 cm per meter.
 14. The floor panel ofclaim 1, wherein the floor panel has a modulus of elasticity of at least2000 N per square millimeter.
 15. The floor panel of claim 1, whereinthe overall thickness of the floor panel is situated between 3.5 and 6mm.